锻压技术

基于DEFORM数值仿真的钢质活塞塑性成形过程缺陷预测及模具优化

英文标题：Defect prediction and die optimization on steel piston plastic forming process based on DEFORM numerical simulation

作者：赵玉琳王培吉闫利军金广山许胜张小磊冯金龙

单位：1.内蒙古一机集团富成锻造有限责任公司技术部 2.内蒙古科技大学理学院

关键词：金属塑性成形模具设计缺陷预测钢质活塞 DEFORM软件

分类号：TG312

出版年,卷(期):页码：2022,47(6):87-92

摘要：

针对钢质活塞成形质量难题，在毛坯研制阶段采用CAE的DEFORM软件开展仿真研究，模拟活塞锻造的金属塑性成形过程，预测模具的填充效果、锻造负荷、锻造过程中产生的缺陷。在模具制造前，预测产品的整个成形过程，可帮助研判潜在的缺陷问题，优化模具设计。提供了从产品设计到生产的完整解决方案，极大地缩短了研发周期，降低了研发及生产成本，改变了以往设计人员凭借主观设计模具、然后多次试制及改进的研发模式，达到了预期效果。通过工业试制一次成功，并且图纸尺寸、表面质量、力学性能等各项技术指标均满足设计要求。目前，富成锻造有限责任公司已全面在研发新产品上推广使用CAD/CAE/CAM数字化设计、制造技术，取得了显著的经济效益。

For the forming quality problem of steel piston, the simulation research was conducted in the blank development stage by DEFORM software of CAE, and the metal plastic forming process of piston forging was simulated to predict the filling effect of mold, the forging load and the defects produced in forging process. Before the mold manufacturing, the prediction of the whole forming process for product could help to judge the potential defect problem and optimize the mold design. The complete solution scheme from product design to production was provided, the research and development cycle was greatly shortened, the cost of research and developement and production was reduced, this research and development mode that the designers subjectively designed the mold, and then tried many times to improve was changed, and achieved the expected results. The first trial production was successful by industrial trial production, and various technical indicators such as drawing size, surface quality and mechanical properties met the design requirements. At present, Fucheng Forging Co.，Ltd. has comprehensively promoted the use of CAD/CAE/CAM digital design and manufacturing technology in the research and development of new products, and has achieved significant economic benefits.

基金项目：

赵玉琳（1968-），男，学士，研究员级高级工程师 E-mail：zhaoyulin86@sohu.com

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